1. ME 59700 Spring 2015 Systems Engineering, Part II
Session 21
31 March 2015
Mr. Larry Hopp, CPL

2. Measures of Producibility
Manufacturability
More quickly and inexpensively produced
Manufacturing lead time
Set up time, operational and nonoperational time
Production time per unit
Significant in terms of cost and profit
Continuous improvement

3. Measures of Producibility
Market Measures
Flow of finished goods to the consumer
PHS&T
Delivery and installation
Environmentally sustainable
Cost of processing to the consumer
Packaging, easily handled, transportable

4. Measuring Manufacturing Progress
Repetition
Production process
Reduction in the time to produce a unit
Increase in the rate at which selected activities are preformed
Corresponding increase in the number of units produced
Reduction in the overall time in process
Reduction in the cost per unit

5. Measuring Manufacturing Progress
Repetition
Learning Curve
Graphical representation of an increase of learning with experience
Labor hours will decrease

6. Figure 16.3 Sample learning curves for production batches of 10.

7. Design for Producibility
Producibility is more comprehensive than manufacturability
Includes packaging and transportation
Characteristic of design

8. Producibility Measure of the relative ease of manufacturing
What does this mean to you?
Design engineering, NOT manufacturing, is the technical group responsible for producibility.
Program offices and design engineers often dislike producibility because it usually requires performance functionality sacrifices, especially if cost is a set value. (Cost as an independent Variable , (CAIV)).

9. Producibility
Many design engineers do not have proper training or experience in designing for producibility.
Manufacturing facilities must be explicitly recognized as a major design constraint.
This includes process capabilities and rate capabilities at each facility.

10. Producibility Principles
Simplicity of design
Economical materials
Economical manufacturing techniques
Standardize materials and components
Process repeatability
Product inspectability
Acceptable materials and processes

11. Producibility Objectives
Minimize procurement lead time
Minimize scrap, chips, and waste
Minimize energy consumption
Reduce part count
Design to a low skill level for manufacturing
Minimize test systems
Use appropriate tolerances

12. Producibility Design Producibility Engineering Plan
Transition from Concept exploration to low rate initial production
Purpose to ensure that material designs reflect good producibility considerations prior to release to manufacturing.

13. Classification of Manufacturing Processes
Forming
Deforming
Removing
Joining
Material properties modifications

16. Manufacturability Principles
Design
Gravity
Fewer parts
Ease of fabrication
Reduce nonstandard parts
More functionality per part.

17. Manufacturability Principles
Assembly
Automatic inserters
Preoriented parts
Sudden and frequent changes in assembly direction
Process compliance
Accessibility
Handling

18. Manufacturability Principles
Guidelines
Foundation
As few positions as possible
Independently replaceable
Order assembly
Commonality in design

19. Manufacturing & Demanufacturing Issues
Reuse
High manufacturing cost
Remanufacturing
Refurbish or partial rebuilding
Recovery
Raw materials or reusable components

20. Figure 16.4 A production system with demanufacturing and disposal.

21. Engineering Change Proposal (ECP)
During Production
Impacts?
Production line
Reliability/Maintainability
Logistics Support
Disposal

22. Figure 5.11 Change control process.

23. Transition to Production
EDM to a production model
Production Plan
Standard components
New manufacturing technology
Special tooling
New assembly and test training
Automated production equipment
Tolerances good enough for full production
Can you test before final assembly
Configuration management

24. Transition to Production
EDM to a production model
Logistics support planning
Change in size, weight, wiring, parts, materials, internal interfaces, assembly and test procedures.
Customer inputs

25. Production Considerations
Inventory
Raw Materials
Just in time
Warehouse space
Work in progress or in-process inventory
Completed Product Storage
Scrap
Cost
Shipping

26. Production Considerations
Skilled workers
Set up Time
Constraints
Scheduling
Continuous/Intermittent/Special Projects
Equipment layout
Identifying all work steps
Quality Control
Testing

27. Thursday 9 April Tuesday 14 April Tuesday 21 April Homework Ch 16
Problems 4 (List and describe 3), 6, 7 (some = 2), 15 (some = 1), 21
Tuesday 14 April
Quiz Ch 16
Tuesday 21 April
CP 4